Boeing ASB 747-21A2577: Revision 1, text

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Page 1Open in PDF

~BOEING Commercial Airplanes 747 Service Bulletin -------------ALERT------------- Number:

Original Issue:

Revision 1:

ATASystem :

SUBJECT:

747-21A2577 February 18, 2020 March 09, 2022 2161 AIR CONDITIONING - Zone Temperature Control System - Trim Air Diffuser Duct Inspection/ Replacement EXPORT CONTROLLED - This technology or software is subject to the U.S. Export Administration Regulations (EAR), (15 C.F.R. Parts 730-774) . No authorization from the U.S. Department of Commerce is required for export, re-export, in-country transfer, or access EXCEPT to country group E:1 or E:2 countries/persons per Supp.1 to Part 7 40 of the EAR.

Treatment of this document and its content is governed by contract with Boeing. Rights to use this document are licensed on a per aircraft basis and such rights may not be transferable. For more information, contact The Boeing Company .

Boeing , the Boeing signature , the Boeing symbol, 707, 717, 727, 737, 747, 757, 767, 777, 787, Dreamliner, BBJ, DC-8, DC-9, DC-10, KC-10, KC-46, KDC-10, MD-10, MD-11, MD-80, MD-88, MD-90, P-8, Poseidon and Boeing liveries are all trademarks owned by The Boeing Company; and no trademark license is granted in connection with this document unless provided in writing by Boeing .

Original Issue: February 18, 2020 Revision 1: March 09, 2022

3.0 747-21A2577 1 of 66

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BOEING SERVICE BULLETIN 747-21A2577 ALERT Original Issue: February 18, 2020 Revision 1: March 09, 2022

ALERT 747-21A2577 2 of66

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BOEING SERVICE BULLETIN 747-21A2577

ALERT ALERT Table of Contents

Revision Transmittal Sheet5

Summary9

1. PLANNING INFORMATION13

A. Effectivity13

1. Airplanes13

2. Spares Affected17

B. Concurrent Requirements17

C. Reason17

D. Description18

E. Compliance18

F. Approval23

G. Manpower23

H. Weight and Balance Changes24

I. Electrical Load Data24

J. References24

1. Existing Data :24

2. Data Supplied with this Service Bulletin :24

3. Installation Drawings Used in the Preparation of this Service Bulletin :24

K. Publications Affected25

L. Interchangeability and lntermixability of Parts25

M. Software Accomplishment Summary25

2. MATERIAL INFORMATION27

A. Material - Price and Availability27

B. Industry Support Information27

C. Parts Necessary for Each Airplane27

1. Kits/Parts :27

2. Parts and Materials Supplied by the Operator:27

3. Parts Modified and Reidentified:30

4. Parts Removed and Not Replaced :30

D. Parts Necessary to Change Spares30

E. Special Tooling - Price and Availability30

F. Special Tooling Necessary to do this Service Bulletin30

3. ACCOMPLISHMENT INSTRUCTIONS31

A. GENERAL INFORMATION31

B. WORK INSTRUCTIONS33

FIGURE 1: TADD AND LOWER SIDEWALL RISER DUCT SEPARATION39

FIGURE 2: TADD AND LOWER SIDEWALL RISER DUCT JOINING41

APPENDIX A: ORIGINAL FIBERGLASS FABRIC MATERIAL TADD ASSEMBLY PART NUMBERS ... 43 APPENDIX B: HIGH TEMPERATURE COMPOSITE MATERIAL TADD ASSEMBLY PART NUMBERS. 45 APPENDIX C: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE: TABLE 1: ORIGINAL FIBERGLASS FABRIC MATERIAL TADD INSPECTION & REPLACEMENT [Group 1, Configuration 1) . 46 APPENDIX D: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 2: HIGH TEMPERATURE COMPOSITE MATERIAL TADD INSPECTION/ REPLACEMENT [Group 1, Configuration 2)

.49

APPENDIX E: LOGIC DIAGRAM FOR PARAGRAPH 1.E., COMPLIANCE : TABLE 3: HIGH TEMPERATURE

COMPOSITE MATERIAL TADD INSPECTION/ REPLACEMENT [Group 2)52

747-21A2577 3 of66

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BOEING SERVICE BULLETIN 747-21A2577

ALERT ALERT

APPENDIX F: REPORT TO THE BOEING COMPANY AFTER INSPECTION(S)56

I APPENDIX G: 747 CLASSIC AND 747-400 FREIGHTER AIRPLANES- HIGH TEMPERATURE COMPOSITE

MATERIAL TADD PART NUMBERS57

747-21A2577 4 of66

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~BOEING Commercial Airplanes 747 Service Bulletin -------------ALERT------------- Number:

Original Issue:

747-21A2577 February 18, 2020 March 09, 2022 2161 Revision Transmittal Sheet Revision 1:

ATASystem :

SUBJECT: AIR CONDITIONING - Zone Temperature Control System - Trim Air Diffuser Duct Inspection/ Replacement This revision includes all pages of the service bulletin .

COMPLIANCE INFORMATION RELATED TO THIS REVISION RC: Start Federal Aviation Administration (FM) Airworthiness Directive AD 2021-07-09 is related to Requirements Bulletin 747-21A2577 RB.

The Federal Aviation Administration (FM) will possibly release an additional Airworthiness Directive related to this service bulletin . The Airworthiness Directive will make the compliance tasks and times given in this service bulletin mandatory .

Effects of this Revision on airplanes on which the Original Issue of Requirements Bulletin 747-21A2577 RB was previously done:

None.

NOTE: Compliance times changes for the required actions have been made. Operators are encouraged to review COMPLIANCE for impact to bulletin accomplishment schedule.

RC:End

REASON FOR REVISION RC: Start This revision is sent to remove the interim structural inspections of the center fuel tanks and add new instructions with updated compliance times to inspect and replace the Trim Air Diffuser Duct (TADD) .

These sections were changed:

RC:End

- In Summary, Background : Removed interim structural inspections information and added related Fleet Team Digest (FTD) reference.

- In Summary, Action : Added TADD replacement task.

- In Summary, Illustration : Added TADD replacement task.

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BOEING SERVICE BULLETIN 747-21A2577 ALERT

- In Airplanes : Added reference to APPENDIX G.

ALERT

- In Paragraph 1.C., Reason: Removed interim structural inspections and added reason for revisions statement, Information Notice statement and related Fleet Team Digest {FTD).

- In Paragraph 1.D., Description : Added effects of this revision statement and TADD replacement task.

RC: Start

- In Compliance: Added new Airworthiness Directive (AD) reference and updated compliance tables.

- In Approval : Updated "European Aviation Safety Agency" name as "European Union Aviation Safety Agency" .

Changed Alternative Method Of Compliance (AMOC) data to reference new AD.

RC:End

- In Paragraph 1.G., Manpower: Updated table.

- In Paragraph 1.J.1., Existing Data : Updated References .

- In Paragraph 1.K., Publications Affected : Updated Damaged Tolerance Based Structural Inspections statement.

- In paragraph 2.B., Industry Support Information : Updated warranty statement.

- In Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin : Eddy Current Instrument & Probe removed.

RC: Start

- In GENERAL INFORMATION: Changed General Notes.

- In WORK INSTRUCTIONS : Removed interim inspection structural inspections and updated work procedures and work instructions tables.

RC:End

- In APPENDIX C, D and E: Logic diagrams updated to match updated compliance.

- In APPENDIX F: Removed Center Wing Tank inspection information.

- In APPENDIX G: Added Appendix with information about High Temperature Composite Material Trim Air Diffuser Duct (TADD) part numbers.

The data given in Information Notices 747-21A2577 IN 01 and 747-21A2577 IN 02 are included in this revision.

RC: Start Vertical lines are put on the left edge of each page, except in Paragraph 1.A., Effectivity and format changes, to show the location of all content changes.

Pages with no vertical lines have no changes.

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BOEING SERVICE BULLETIN 747-21A2577 ALERT

REVISION HISTORY Service Bulletin Service Bulletin Requirement Bulletin 747-21A2577 747-21A2577 747-21A2577 RB Issue Date Original Issue: February 18, 2020 Original Issue:

Revision 1: March 09, 2022 Revision 1:

ALERT Requirement Bulletin 747-21A2577 RB Issue Date February 18, 2020 March 09, 2022 747-21A2577 7 of66

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BOEING SERVICE BULLETIN 747-21A2577 ALERT Original Issue: February 18, 2020 Revision 1: March 09, 2022

ALERT 747-21A2577 8 of66

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~BOEING Commercial Airplanes 747 Service Bulletin -------------ALERT------------- Number:

Original Issue:

Revision 1:

ATASystem :

747-21A2577 February 18, 2020 March 09, 2022 2161 Summary SUBJECT: AIR CONDITIONING - Zone Temperature Control System - Trim Air Diffuser Duct Inspection/ Replacement

THIS DOCUMENT IS SENT TO THE OPERATORS OF RECORD OF THE AIRPLANES SHOWN IN PARAGRAPH 1.A., EFFECTIVITY . IF AN AIRPLANE HAS BEEN LEASED OR SOLD, SEND THIS DOCUMENT TO THE NEW OPERA TOR. IF APPLICABLE SPARES HAVE BEEN SOLD, SEND THIS DOCUMENT TO THE NEW OWNER. THIS IS AN ENHANCED REQUIRED FOR COMPLIANCE DOCUMENT . THE BOEING

PROCESSES USED TO CREATE THE SERVICE BULLETIN (SB) AND THE REQUIREMENTS BULLETIN (RB) ENSURE THAT THE INFORMATION BETWEEN "RC START" AND "RC END" IN THE SB ARE IDENTICAL TO THE INFORMATION IN THE SAME SECTIONS (COMPLIANCE, WORK INSTRUCTIONS ... ) OF THE RB WHICH THE SB REFERS TO AS THE RELATED DOCUMENT .

CONCURRENT REQUIREMENTS None.

BACKGROUND This service bulletin gives instructions to do a Detailed Inspection of original fiberglass fabric material and high temperature composite material Trim Air Diffuser Duct (TADD) for damage, and do applicable on-condition actions . If this service bulletin is not done, potential hot air leakage from original fiberglass fabric material or high temperature composite material TADD can possibly cause damage to the wing center section fuel tank secondary fuel barrier coating and primary sealant, which can result in fuel leakage into an ignition zone and result in a fire or explosion.

Boeing Service Bulletin (SB) 747-21A2418 was issued in 2002 to inspect the original fiberglass fabric material TADDs for hot air leakage and replace if necessary . Airworthiness Directive (AD) 2007-07-03 provided closure of the inspection requirements after the installation of the high temperature composite material TADDs . However, operators reported high temperature composite material TADDs have failed . Follow-up maintenance reported the high temperature composite material TADDs were ruptured with damaged insulation in poor condition . Yet, there had not been any report of damage to fuel tank secondary fuel barrier coating and primary sealant, or fuel leakage due to a damaged TADD in the Boeing 747 fleet. Hot trim air is causing both original fiberglass fabric material and high temperature composite material T ADDs material properties degradation, which potentially causes hot air leakage from the TADD(s) .

Accomplishment of this service bulletin will enable detection and prevention of potential hot air leakage from damaged TADD made of original fiberglass fabric material and high temperature composite material.

Boeing Service Related Problem (SRP) 747-SRP-21-0270 is related to this service bulletin .

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BOEING SERVICE BULLETIN 747-21A2577

ALERT ALERT I Boeing Fleet Team Digest (FTD) 747 FTD 21-19002 is related to this service bulletin .

This table is provided to operators for planning purposes only. Refer to the applicable sections for more information.

Planning Data Affected Data Module Reference Spares Affected No Paragraph 1.A.2., Spares Affected AD Related Yes Refer to Requirements Bulletin 747-21A2577 RB Weight and Balance Changed No Paragraph 1.H., Weight and Balance Changes Electrical Load Changed No Paragraph 1.1., Electrical Load Data Publications Affected No Paragraph 1.K., Publications Affected Airplane Flight Operations Affected No Paragraph 1.K., Publications Affected (Flight Crew Operations Manual and/or FAA Approved Airplane Flight Manual) Kits/Parts Required No Paragraph 2.C.1., Kits/Parts Operator Supplied Parts/Material Yes Paragraph 2.C.2., Parts and Materials Supplied by the Operator Special Tooling Required Yes Paragraph 2.F., Special Tooling Necessary to do this Service Bulletin ACTION Open access. Do a Detailed Inspection of original fiberglass fabric material and high temperature composite I material Trim Air Diffuser Ducts (TADD) for damage, and do a replacement of the TADD(s) and applicable on-condition actions. Close access.

EFFECTIVITY 747-100, 747-100B, 747-100B SUD, 747-200B, 747-200C, 747-200F, 747-300, 747-400, 747-400D, 747-400F, 747SP, 747SR Airplane(s). Refer to Paragraph 1.A.1., Airplanes, for the list of affected airplane(s) .

COMPLIANCE Refer to Paragraph 1.E., Compliance.

INDUSTRY SUPPORT INFORMATION Refer to Paragraph 2.B., Industry Support Information.

MANPOWER Refer to Paragraph 1.G., Manpower.

MATERIAL INFORMATION Refer to Paragraph 2.A., Material - Price and Availability .

747-21A2577 10 of 66

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BOEING SERVICE BULLETIN 747-21A2577

ALERT ALERT OPEN ACCESS. DO A

DETAILED INSPECTION OF

ORIGINAL FIBERGLASS

FABRIC MATERIAL AND HIGH

TEMPERATURE COMPOSITE

MATERIAL TADD FOR

DAMAGE, AND DO A

REPLACEMENT OF THE

TADD(S) AND APPLICABLE

ON-CONDITION ACTIONS CLOSE ACCESS. (TYPICAL) 2884216 Original Issue: February 18, 2020 Revision 1: March 09, 2022 Export Controlled ECCN: 9E991 141-21A2011 Copyright © Unpublished Work - See page 1 for details. 11 of 66

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BOEING SERVICE BULLETIN 747-21A2577 ALERT Original Issue : February 18, 2020 Revision 1: March 09, 2022

ALERT 747-21A2577 12 of 66

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